Kawasaki EX500 Streetfighter Mods

[SuperBlow420]

@oldchevy4x4

How did you secure the sheet metal for the electronics to the frame?

[oldchevy4x4]

@SuperBlow420

Self drilling/tapping machine screws into the under-side of the frame

[rmsusic]

hello. what were your schematics to front turn signals? on my universal turn lights, i have a black with white stripe and black. from my bike there is black with yellow stripe, grey, blue, and green. know the connections? is this familiar to you? thanks

[oldchevy4x4]

@rmsusic

Black/yellow is ground, grey & green should be the high filament (turn) and blue should be the low filament (running lights). If your new lights only have 2 wires they are probably (unless they ground through the housing) single filament type lights... that is to say they are only on & off, not on for running then brighter for signaling.

Check out ex-500.com's wiki section for wiring diagrams

[rmsusic]

how did you do your wiring for front turn signals? 

[oldchevy4x4]

@rmsusic

I cut & extended the factory harness. The wires are un in a black sleeve to conceal & protect them.

[rmsusic]

where can i get the universal side mount clamps? thanks

[oldchevy4x4]

@rmsusic

For the headlights? ebay, denniskirk, jcwhitney... etc.

[jaideng1234]

Where did you get the sidemount clamps?

[JordamusPrime]

Nice bike! Wish I had the know how to be able to do this to my 2006.

[bma852]

You are a genius. this bike is off the chain!

[smotleyjr79]

i keep bothering you with questions but you do good work... I bought a round headlight for my ninja and it came with a white and black wire, how did you rewire yours to the round healdlight? the factory has 3 wires.

[oldchevy4x4]

@smotleyjr79

I don't mind questions at all. If your headlight only has 2 wires, it is a single filament bulb. That is to say. no high/low beam... just one kind of like a fog or driving light. I'd really recommend a dual filament high/low light, but there are many people using a single beam light. In your light's case the black would be a ground, and the white would be hot. I don't have the schematic on this pc, but if you have a test light you could figure which stock wire is which

[smotleyjr79]

Did you get rid of your Air switching valve? Mine was off when I bought it but I'm having issues finding out which hoses goes where to attach to the petcock/fuel valve, where is the gas hose and what is the second valve on the petcock for? I only see one hose that hooks to both carbs.

[oldchevy4x4]

@smotleyjr79 There are 2 barbs that connect to both cabs. The lower one, closer to the seat should be the fuel inlet... from the petcock. The upper one, closer to the front tire would be the bowl vent. The left carb vacuum barb operates the petcock, the right carb's vacuum barb operates the PAIR system. The whole ari re-circulation system is not necessary; except for emissions. With aftermarket exhausts, it can also create backfiring/popping on deceleration

[smotleyjr79]

where did you get the tail light?  what is it off of?

[oldchevy4x4]

@smotleyjr79

The tail light is a grommet mount trailer/truck light. They can be found in different configurations/lense types at auto parts or farm stores

[smotleyjr79]

what did you use to mount the speedometer? 

[oldchevy4x4]

@smotleyjr79

The Honda speedo had its own bracket, I had to make 2 brackets from some light steel to mount that to the tripple tree.

[bjshredder]

LOL ... "The FOG mod." Bill will be famous forever. ;-)

[eburt6]

Really cool build. Finished product looks excellent. Good work!

[ChrisBurgess1992]

Keep tapping the send buttonon my iPod :@ I intend to do something similar to the vid but put my own twist on it, does anyone no what tanks will fit on a ex 500 that will fit straight on?

[oldchevy4x4]

@ChrisBurgess1992

I really don't know, but I'm sure you could fab up a different bracket for another tank. Overall tank dimensions would be the key

[ChrisBurgess1992]

Jw if you used the same tank or did you get one off a different bike because I am str

[ChrisBurgess1992]

Nice bike

[CS05HHO]

I don't like the seat, it looks like the 60's it looks very clasic and verry anoying.... i like the front part of the bike, i think you should consider remodeling the rear end! good luck!

[indeliblehiphop]

Nice job, are the mirrors cutom?

[oldchevy4x4]

@indeliblehiphop

Thanks! The mirrors are made by EMGO. Available on ebay, thru JC whitney and Dennis Kirk...etc.

[out2kill3652b]

do your speedometer lights work?

[oldchevy4x4]

@out2kill3652b

Yup, the back-light works.

[out2kill3652b]

@oldchevy4x4 looks like im gonna have to wire something up lol

[ellomirza]

You're a mechanical genius.

[indeliblehiphop]

@ellomirza Agreed.

[equipt31]

i didnt see this in the description or other comments but what speedo exactly did you use from an old honda? i have an 09 500r that i am making into a fighter and the speedo is the toughest thing for me to keep cheap, im trying to find something besides a trail tech gauge and some other cheap, small, oem part would be perfect. i heard bicycle speedos may work too?

[oldchevy4x4]

@equipt31 I couldn't tell you what model Honda the speedo is from... it was an ebay find that was simply listed as a 70's Honda speedometer. Nearly any cable driven speedo from a Japanese bike will work, although you may need to extend your cable (I had to). I have no idea about a bike speedo, so I can't help ya there.

[out2kill3652b]

how do you remove the stock headlight?

[oldchevy4x4]

@out2kill3652b You need to remove the front fairing to access the cage/bracket that holds the gauges and the light.

[out2kill3652b]

@oldchevy4x4 i did that, i had everything stripped down, but the bulb refused to come out. my friend knew more about it than i did and was able to take it off. thanks for the response though

[Nimbly]

Pretty cool man. The ONLY thing is that you should have used the twin side by side headlights.

[beercoolie]

@Nimbly---- or over and under flat headlights and a dual sport front fender..

[Nimbly]

@beercoolie Totally. I would help the street fighter attitude.

[seans1997]

when you re geared it did it make it go faster

also did you block the top hole in the air box

[oldchevy4x4]

@seans1997 It is geared for acceleration, some top speed was lost. I used a rubber grommet to plug the hole in the airbox.

[seans1997]

when you re geared it did it make it go faster



[seans1997]

where you get the mirrors

[oldchevy4x4]

@seans1997

ebay

search EMGO bar end mirrors

[chobies]

@seans1997 i got very similar ones off amazon like $14

[onethatworked]

hey nice warrior, i was wondering if you could give me some info on thos emissions plates you made. i.g. how thick of aluminum u used?, and if you shaped them with a grinder or what? im planing a streetfighter mod on my 89 ZX-6R and need that hole ugly air box gone for the new filters

[oldchevy4x4]

@onethatworked I made the plates out of 1/8" aluminum that I had on hand. I traced the factory barb bases, and cut to fit. I rough cut them with a cut off wheel, then did the detail work with a Dremel.

[MuayThaiMMAjunkie]

sicccckkkkk!!!! dude, do you own a shop? I was thinking of buying a 500 as my first bike and make it look like this. It'll be mainly for commuting. 80% fwy/ 20% city.

[oldchevy4x4]

@MuayThaiMMAjunkie

Thanks man, no bike shop... just a little shed LoL. The EX is a great bike to start on, and makes a stellar commuter.

[afgr173]

did you have to adjust the seat at all or did you just throw in the metal? by the way I am only trying to imitate your bike because when I dream your bike is what I dream of haha

[oldchevy4x4]

@afgr173 With the metal being being under the frame rails, everything clears fine. I had toyed with placing the sheet metal in-between the frame rails, but it was too close for comfort IMO. Good luck with your build!